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| United States Patent |
5,508,053
|
|
Villota
, et al.
|
April 16, 1996
|
Method for producing vegetable pasta
Abstract
A method is provided for the production of vegetable or herb pasta,
especially thin-walled vegetable or herb pasta, containing high levels of
vegetable solids, i.e., about 4 to about 15 weight percent vegetable
solids, or high levels of herb solids, i.e., about 2 to 15 weight percent
herb solids. Vegetable pasta can be prepared using vegetable solids
derived from beet, broccoli, carrot, celery, corn, green pepper, red
pepper, spinach, tomato, and the like. Herb pasta can be prepared using
herb solids derived from oregano, basil, coriander, tarragon, onion,
parsley, sage, garlic, and the like. Such vegetable and herb pastas are
produced by carefully drying the formed pasta shapes under high
temperature and low relative humidity conditions, whereby the vegetable or
herb pasta is obtained with a moisture content of about 11 to about 13
weight percent and vegetable solids content of about 4 to about 15 weight
percent or herb solids content of about 2 to about 15 weight percent,
wherein the pasta has, after processing and subsequent cooking, good
color, texture, integrity, and vegetable or herb flavor. The vegetable and
herb pastas produced by this method also have excellent storage stability.
| Inventors:
|
Villota; Ricardo (Lake Zurich, IL);
Maksimoski; Richard C. (Gurnee, IL);
Irvin; Scot A. (Grayslake, IL)
|
| Assignee:
|
Kraft Foods, Inc. (Northfield, IL)
|
| Appl. No.:
|
317997 |
| Filed:
|
October 4, 1994 |
| Current U.S. Class: |
426/557; 426/451 |
| Intern'l Class: |
A23L 001/16 |
| Field of Search: |
426/557,451
|
References Cited
U.S. Patent Documents
| 466230 | Dec., 1891 | Gent.
| |
| 1355731 | Oct., 1920 | Bloch.
| |
| 2037042 | Apr., 1936 | Perewe | 99/85.
|
| 3082092 | Mar., 1963 | De Felice | 99/85.
|
| 3780186 | Dec., 1973 | Troy | 426/93.
|
| 3843818 | Dec., 1972 | Wren et al. | 426/346.
|
| 3992554 | Nov., 1976 | Blake et la. | 426/557.
|
| 4088790 | May., 1978 | Bevan et al. | 426/96.
|
| 4517215 | May., 1985 | Hsu | 426/557.
|
| 4840808 | Jun., 1989 | Lee et al. | 426/270.
|
| 4871572 | Oct., 1989 | Chiu et al. | 426/557.
|
| 4874619 | Oct., 1989 | Leonardo et al. | 426/94.
|
| 5087470 | Feb., 1992 | Sarabhai | 426/557.
|
| 5124168 | Jun., 1992 | McMillin et al. | 426/557.
|
| 5211977 | May., 1993 | Hauser et al. | 426/557.
|
| 5252351 | Oct., 1993 | Cox | 426/549.
|
| 5294454 | Mar., 1994 | Guarneri | 426/557.
|
| Foreign Patent Documents |
| 0350552A1 | Jan., 1990 | EP | .
|
| 0445550B1 | Mar., 1990 | EP | .
|
| 0518097A1 | Dec., 1992 | EP | .
|
| 0536982A2 | Apr., 1993 | EP | .
|
| 1729398A1 | Apr., 1992 | SU.
| |
Other References
Database WPI Week 8533, Derwent Publications Ltd., London, GB; AN85-200230
& JP-A-60 126 043 (Showa Sangyo KK) 5 Jul. 1985--Abstract.
Giese, "Pasta: New Twist on an Old Product", Food Technology--Feb. 1992,
pp. 118-126.
|
Primary Examiner: Czaja; Donald E.
Assistant Examiner: Tran; Lien
Attorney, Agent or Firm: Fitch, Even, Tabin & Flannery
Parent Case Text
RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser.
No. 08/106,217, filed on Aug. 13, 1993 now abandoned, which is hereby
incorporated by reference.
Claims
That which is claimed is:
1. A method of preparing vegetable or herb pasta containing about 4 to
about 15 weight percent vegetable solids or about 2 to 15 weight percent
herb solids, said method comprising
(1) blending flour, vegetable or herb solids, and water to form a
homogenous paste with a water content of about 28 to about 33 weight
percent, wherein the flour has a minimum average protein content between
about 12 to about 13.5 weight percent;
(2) extruding the homogenous paste to form pasta-shaped extrudates; and
(3) drying the pasta-shaped extrudates, whereby a vegetable or herb pasta
is obtained with a moisture content of about 11 to about 13 weight percent
and vegetable solids content of about 4 to about 15 weight percent or herb
solids content of about 2 to 15 weight percent,
wherein the drying step comprises
(a) drying the pasta-shaped extrudates at a temperature of about 65.degree.
to about 85.degree. C. and a relative humidity of about 25 to about 60
percent for a time sufficient to form a partially-dried vegetable or herb
pasta with a moisture content of less than about 27 weight percent, and
(b) drying the partially-dried vegetable or herb pasta at a temperature of
about 75.degree. to about 115.degree. C. and a relative humidity of about
26 to about 60 percent for a time sufficient to dry the vegetable or herb
pasta; and wherein the vegetable or herb pasta has, after processing and
subsequent cooking, good color, texture, integrity, and vegetable or herb
flavor.
2. A method as defined in claim 1, wherein the pasta contains vegetable
solids derived from a vegetable selected from the group consisting of
beet, broccoli, carrot, celery, corn, green pepper, red pepper, spinach,
and tomato.
3. A method as defined in claim 2, wherein the vegetable solids used to
form the homogenous paste are in an encapsulated form.
4. A method as defined in claim 2, wherein the pasta is a thin-walled
pasta.
5. A method as defined in claim 4, wherein the flour is selected from the
group consisting of durum flour, semolina flour, hard red spring flour,
and mixtures thereof.
6. A method as defined in claim 4, wherein the pasta contains vegetable
solids which in step (1) are in a powder form.
7. A method as defined in claim 4, wherein the pasta contains vegetable
solids which in step (1) are in an aqueous slurry form.
8. A method as defined in claim 1, wherein the pasta contains herb solids
derived from a herb selected from the group consisting of oregano, basil,
coriander, tarragon, onion, parsley, sage, and garlic.
9. A method as defined in claim 8, wherein the pasta is a thin-walled
pasta.
10. A method as defined in claim 8, wherein the herb is an individually
quick frozen herb present at about 2 to 5 weight percent.
11. A method as defined in claim 8, wherein the herb is a gently-dried herb
present at about 4 to 15 weight percent.
12. A method as defined in claim 9, wherein the flour is selected from the
group consisting of durum flour, semolina flour, hard red spring flour,
and mixtures thereof.
13. A method as defined in claim 8, wherein the herb solids used to form
the homogenous paste are in an encapsulated form.
14. A method as defined in claim 1, wherein the flour is selected from the
group consisting of durum flour, semolina flour, hard red spring flour,
and mixtures thereof.
15. A method as defined in claim 2, wherein the flour comprises a blend of
about 50 to about 100 percent by weight durum flour and up to about 50
percent by weight hard red spring flour or a blend of 50 to about 100
percent by weight semolina flour and up to about 50 percent by weight hard
red spring flour.
16. A method as defined in claim 1, wherein the pasta contains vegetable
solids which in step (1) are in a powder form.
17. A method as defined in claim 1, wherein the pasta contains vegetable
solids which in step (1) are in an aqueous slurry form.
18. A method as defined in claim 1, wherein the pasta contains vegetable
solids which are derived from a vegetable selected from the group
consisting of broccoli, celery, green pepper, and spinach and wherein the
pH of the homogenous paste is adjusted from about 5 to about 9.
19. A method as defined in claim 18, wherein the pH of the homogenous paste
is adjusted from about 6 to about 8.
20. A method as defined in claim 1, wherein the pasta contains herb solids
which are derived from a herb selected from the group consisting of basil,
oregano, and coriander and wherein the pH of the homogenous paste is
adjusted from about 5 to about 9.
21. A method as defined in claim 20, wherein the pH of the homogenous paste
is adjusted from about 6 to about 8.
22. A method as defined in claim 1, wherein the vegetable or herb solids
used to form the homogenous paste are in an encapsulated form.
23. A method of preparing a thin-walled vegetable or herb pasta containing
about 4 to about 15 weight percent vegetable solids or about 2 to 15
weight percent herb solids, said method comprising
(1) blending flour, vegetable or herb solids, and water to form a
homogenous paste with a water content of about 28 to about 33 weight
percent, wherein the flour is is selected from the group consisting of
durum flour, semolina flour, hard red spring flour, and mixtures thereof
and has a minimum average protein content between about 12 to about 13.5
weight percent and wherein the vegetable solids are derived from a
vegetable selected from the group consisting of beet, broccoli, carrot,
celery, corn, green pepper, red pepper, spinach, and tomato or wherein the
herb solids are derived from a herb selected from the group consisting of
oregano, basil, coriander, tarragon, onion, parsley, sage, and garlic;
(2) extruding the homogenous paste to form thin-walled, pasta-shaped
extrudates; and
(3) drying the thin-walled, pasta-shaped extrudates, wherein
(a) the thin-walled, pasta-shaped extrudates are first dried at a
temperature of about 65.degree. to about 85.degree. C. and a relative
humidity of about 25 to about 60 percent for a time sufficient to form a
first partially-dried, thin-walled vegetable or herb pasta with a moisture
content of less than about 27 weight percent,
(b) the first partially-dried, thin-walled vegetable or herb pasta is then
dried at a temperature of about 75.degree. to about 115.degree. C. and a
relative humidity of about 26 to about 60 percent for a time sufficient to
form a second partially-dried, thin-walled vegetable or herb pasta with a
moisture content of less than about 19.0 weight percent, and
(c) the second partially-dried, thin-walled vegetable or herb pasta is
dried at a temperature of about 70.degree. to about 98.degree. C. and a
relative humidity of about 35 to about 60 percent for a time sufficient to
form a thin-walled vegetable or herb pasta with a moisture content of
about 11 to about 13 weight percent and vegetable solids content of about
4 to about 15 weight percent or herb solids content of about 2 to about 15
weight percent, wherein the thin-walled vegetable or herb pasta has, after
cooking, good color, texture, integrity, and vegetable or herb flavor.
24. A method as defined in claim 23, wherein the vegetable or herb pasta is
a vegetable pasta and wherein the vegetable solids in step (1) are in a
powder form.
25. A method as defined in claim 23, wherein the vegetable or herb pasta is
a vegetable pasta and wherein the vegetable solids in step (1) are in an
aqueous slurry form.
26. A method as defined in claim 23, wherein the vegetable or herb pasta is
a herb pasta containing about 2 to about 5 weight percent herb solids and
wherein the herb solids in step (1) are derived from individually quick
frozen herbs.
27. A method as defined in claim 23, wherein the vegetable or herb pasta is
a herb pasta containing between about 4 to about 15 weight percent herb
solids and wherein the herb solids in step (1) are derived from
gently-dried herbs.
28. A method as defined in claim 23, wherein the vegetable or herb solids
used to form the homogenous paste are in an encapsulated form.
29. A method as defined in claim 23, wherein the homogenous paste is
essentially egg-free.
30. A method as defined in claim 23, wherein the homogenous paste is
essentially oil-free.
31. A method as defined in claim 23, wherein the homogenous paste is
essentially egg-free and essentially oil-free.
32. A method of preparing vegetable or herb pasta containing about 4 to
about 15 weight percent vegetable solids or about 2 to 15 weight percent
herb solids, said method comprising
(1) blending flour, vegetable or herb solids, and water to form a
homogenous paste with a water content of about 28 to about 33 weight
percent, wherein the flour has a minimum average protein content between
about 12 to about 13.5 weight percent;
(2) extruding the homogenous paste to form pasta-shaped extrudates; and
(3) drying the pasta-shaped extrudates, whereby a vegetable or herb pasta
is obtained with a moisture content of about 11 to about 13 weight percent
and vegetable solids content of about 4 to about 15 weight percent or herb
solids content of about 2 to 15 weight percent, wherein the drying step
comprises
(a) drying the pasta-shaped extrudates at a temperature of about 65.degree.
to about 85.degree. C. and a relative humidity of about 25 to about 60
percent for a time sufficient to form a first partially-dried vegetable or
herb pasta with a moisture content of less than about 27 weight percent,
(b) drying the first partially-dried vegetable or herb pasta at a
temperature of about 75.degree. to about 115.degree. C. and a relative
humidity of about 26 to about 60 percent for a time sufficient to form a
second partially-dried vegetable or herb pasta with a moisture content of
less than about 19.0 weight percent, and
(c) drying the second partially-dried vegetable or herb pasta at a
temperature of about 70.degree. to about 98.degree. C. and a relative
humidity of about 35 to about 60 percent for a time sufficient to form the
vegetable or herb pasta; and
wherein the vegetable or herb pasta has, after processing and subsequent
cooking, good color, texture, integrity, and vegetable or herb flavor.
33. A method as defined in claim 32, wherein the pasta contains vegetable
solids derived from a vegetable selected from the group consisting of
beet, broccoli, carrot, celery, corn, green pepper, red pepper, spinach,
and tomato.
34. A method as defined in claim 33, wherein the pasta is a thin-walled
pasta.
35. A method as defined in claim 32, wherein the pasta contains herb solids
derived from a herb selected from the group consisting of oregano, basil,
coriander, tarragon, onion, parsley, sage, and garlic.
36. A method as defined in claim 35, wherein the pasta is a thin-walled
pasta.
37. A method as defined in claim 32, wherein the pasta contains vegetable
solids which are derived from a vegetable selected from the group
consisting of broccoli, celery, green pepper, and spinach and wherein the
pH of the homogenous paste is adjusted from about 5 to about 9.
38. A method as defined in claim 37, wherein the pH of the homogenous paste
is adjusted from about 6 to about 8.
39. A method as defined in claim 32, wherein the pasta contains herb solids
which are derived from a herb selected from the group consisting of basil,
oregano, and coriander and wherein the pH of the homogenous paste is
adjusted from about 5 to about 9.
40. A method as defined in claim 39, wherein the pH of the homogenous paste
is adjusted from about 6 to about 8.
Description
FIELD OF THE INVENTION
The present invention generally relates to methods for the production of
vegetable pastas and herb pastas and to the vegetable pastas and herb
pastas so produced. More specifically, this invention provides improved
methods for the production of vegetable-containing or herb-containing
pastas, especially thin-walled pastas, which contain high levels of
vegetable solids or herb solids, respectively. The vegetable pastas and
herb pastas of this invention retain good color, texture, integrity, and
flavor after cooking.
BACKGROUND OF THE INVENTION
Conventional vegetable pastas, such as spinach- and tomato-containing
pastas, consist mainly of wheat flour with only about 3 to 3.5 weight
percent or less vegetable solids. Attempts to prepare wheat flour-based
vegetable pastas with higher vegetable solids levels have generally been
unsatisfactory.
Processes for the commercial manufacture of pasta, including vegetable
pasta with low levels of vegetable solids, are well known. These processes
involve mixing flour and water and, in the case of vegetable pasta, the
appropriate vegetable solids, to form a paste. Typically the paste is
shaped by forcing it through holes in an extruder die at high pressure and
elevated temperature to form extrudates of the desired cross-sectional
shape. The extrudates may, if desired, be cut to desired lengths. The
extrudates are usually dried to a moisture content of generally less than
about 14 weight percent.
The drying process in a conventional pasta manufacturing process is
lengthy. The extrudates as they leave the extruder generally have a
moisture content of about 28 weight percent or higher. For shelf-stable
pasta, the moisture content of the pasta must generally be reduced to
below about 14 weight percent. To accomplish this, conventional long and
short pasta goods are generally dried to a moisture content of about 10 to
13 weight percent under normal drying conditions using temperature in the
range of about 40.degree. to about 60.degree. C. with maximum drying times
of about 10 hours for short pasta goods (i.e., elbow macaroni, elbow
spaghetti, shells, mafalda, and the like) and about 20 hours for long
pasta goods (i.e., spaghetti, fettuccine, vermicelli, and the like). Under
high temperature drying conditions in the range of about 60.degree. to
about 80.degree. C., short pasta goods are dried for a maximum of about 5
hours and long pasta goods are dried for a maximum of about 10 hours. For
ultra high temperature drying conditions in the range of about 80.degree.
to about 140.degree. C., short pasta goods are dried for a maximum of
about 2 hours and long pasta goods are dried for a maximum of 5 hours. In
most cases, the only process parameters controlled are the temperature,
the relative humidity of the drying air and the drying time. In order to
avoid checks, cracks, and like defects in the pasta, the conventional
drying process is a relatively slow and time consuming, often requiring up
to about 36 hours for long goods or 12 hours for short goods, for the
pasta to reach the desired moisture content of less than 14 weight
percent. During much of the drying process, the pasta is subjected to
elevated temperatures which, if vegetable solids are present, adversely
affect the color, flavor, texture and nutritional value of the finished
pasta product.
Incorporation of flavoring and/or coloring agents, such as spinach or
tomato solids, at levels up to about 3 weight percent can sometimes result
in a pasta product with a starchy or gummy texture. Moreover, such
vegetable pastas generally do not retain their color upon shelf aging or
when cooked for eating. Better color can be obtained by increasing the
level of vegetable solids in the pasta accompanied by properly controlled
processing conditions. Attempts to increase the vegetable solids content
above about 3.5 weight percent in dried, shelf-stable pasta have, however,
generally resulted in products which lack integrity and with a tendency to
fall apart during or after cooking. Such pasta also does not have
desirable texture properties and generally, the overall quality is
unacceptable. Thus, commercially available dried vegetable pasta generally
has about 3 to 3.5 weight percent or less vegetable solids, and tends to
change in color and flavor during processing, storage and upon cooking.
Some attempts have been made to preserve or enhance the color in dried
vegetable pasta. For example, U.S. Pat. No. 4,840,808 discloses preparing
vegetable pasta containing about 3 weight percent chlorophyll-containing
vegetable solids and cations selected from the group consisting of
magnesium, zinc, copper, calcium, and aluminum in order to enhance and
preserve the color. The vegetable powders are subjected to an alkaline
treatment prior to addition to the pasta dough in order to hydrolyze the
chlorophyll ester groups and stabilize the chlorophyll pigment. U.S. Pat.
No. 4,517,215 discloses the use of hydrocolloids such as sodium or
potassium alginate, at about 0.25 to 3 weight percent, and propylene
glycol alginates, also at about 0.25 to 3 weight percent, to prepare
vegetable pastas where the main ingredient is a seed or tuberous vegetable
such as corn, potato, beans, and peas. Such vegetable pastas do not
contain significant amounts of wheat-type flour. European Patent
Publication 0,518,097A1 discloses that the color stability of vegetable
pasta can be enhanced by subjecting the fresh pasta to saturated steam at
70.degree. to 80.degree. C. followed by drying at temperatures below
60.degree. C. and a relative humidity of about 75 percent to a final
moisture content of about 11 percent.
As indicated, the amount of vegetable solids in conventional dried
wheat-based pasta has generally been limited to about 3 to 3.5 weight
percent or less. Such vegetable pastas tend to loose color and flavor
during the drying process, upon storage, and especially upon cooking. For
example, green or chlorophyll-containing vegetable pastas, e.g., spinach
pastas tend to turn brown; and the reddish color in tomato pasta tends to
fade over time. Moreover, even if the color remains strong in the dried
pasta, there is generally a substantial loss of color upon cooking. A
general reduction in both flavor and nutritional values is also observed
with conventional vegetable pastas upon storage. The inability to
incorporate higher levels of vegetable solids into dried pasta and to
maintain color and flavor, has also generally limited the types of
vegetables that could be utilized to those with very intense coloration or
pigmentation such as spinach or tomato. In general, flavor retention has
not been a primary concern in commercial vegetable pasta products.
More recently, U.S. Pat. No. 5,124,168 (June 23, 1992) provides a vegetable
pasta having up to about 10 weight percent vegetable or herb solids which
reportably retained enhanced flavor, color, and texture and, when dried,
had a shelf life longer "than flavored pasta products currently in the
market." The basic pasta product contained between about 40 to 80 percent
pasta flour, about 1 to 10 percent egg (e.g., whole egg, egg white from
whole egg, or dehydrated egg white), about 0.2 to 5 percent starch
complexing agent, olive oil in an amount sufficient to facilitate the
extrusion of the pasta product and to bind the non-pasta flour ingredients
to the pasta flour (i.e., about 1 to 5 percent), and sufficient water for
blending. The pasta could contain up to about 10 percent of a "flavor
component" selected from the group consisting of tomato, parsley,
calamari, lemon, garlic, curry, carrot, porcini, mushroom, black pepper,
dill, cilantro, serrano, green pepper, red pepper, tarragon, and
combinations thereof. The pasta could be used fresh or it could be dried
under relatively low temperature and relatively high humidity conditions.
The maximum drying temperature was between about 58.degree. and 70.degree.
C. in order "to protect the organoleptic properties of the formulations."
The reported relative humidity during drying was in the range of about 85
to 92 percent. The drying process consisted of four distinct stages: (1)
an initial pre-drying stage having a preferred temperature of about
30.degree. C. and a preferred relative humidity of about 85 percent; (2) a
pre-drying stage having a preferred temperature of about 30.degree. C. and
a preferred relative humidity of about 85 percent; (3) a drying stage
having several substages over a 14 to 15 hour period; and (4) a
post-drying stage where the pasta is equilibrated with ambient temperature
and humidity conditions. The drying stage included three separate
substages: (1) a "case hardening" substage wherein the pasta product is
subjected to a draft of air to set the exterior shape; (2) a high humidity
substage where the humidity is raised to about 92 percent and where the
temperature is raised to about 70.degree. C., then lowered to about
55.degree. C. and held at that temperature for about 2 hours; and (3) a
final substage wherein the temperature is lowered to about 30.degree. C.
over about a twelve hour period during which time the humidity is also
lowered "in proportion to the drop in temperature." The drying process
should bring the moisture content of the pasta down from about 30 percent
to about 12 percent in about 14 to 15 hours.
The inability to provide vegetable pastas and herb pastas with good
texture, flavor, color and nutritional value as well as good storage
stability has limited the use of such pastas. Fresh vegetable and herb
pastas generally exhibit very limited shelf lives because of their
tendency to undergo chemical changes, including flavor and color
degradation.
It would be desirable, therefore, to provide a method by which dried
vegetable or herb pasta could be prepared with higher levels of vegetable
or herb solids than is currently commercially available. It would also be
desirable to provide dried vegetable or herb pastas with high levels of
vegetable or herb solids, respectively, which have good color, texture,
structural integrity, and vegetable or herb flavors. It would also be
desirable to provide dried vegetable or herb pastas with high levels of
vegetable or herb solids, respectively, which retain their color, texture,
integrity, and vegetable or herb flavor upon cooking. It would also be
desirable to provide dried vegetable or herb pastas with high levels of
vegetable or herb solids, respectively, which are more visually appealing,
i.e., more colorful, in both the dried and cooked state and which are more
flavorful and nutritious than conventional vegetable or herb pastas. It
would also be desirable to provide dried vegetable or herb pastas with
enhanced color and color stability without the need to add color
stabilizers, enhancers, artificial coloring, or other stabilizing
ingredients to the product. It would also be desirable to provide dried
vegetable or herb pastas with improved storage stability. It would also be
desirable to provide such just-described vegetable or herb pastas without
the need to add egg-containing ingredients and/or oil. It would also be
desirable to provide essentially egg-free and/or oil-free vegetable or
herb pastas having high levels of vegetable or herb solids, respectively.
The present invention provides such processes and such dried vegetable and
herb pastas.
SUMMARY OF THE INVENTION
This invention relates to a method by which dried vegetable pasta having
high levels of vegetable solids can be prepared using conventional pasta
making equipment. This invention also relates to a method by which dried
herb pasta having high levels of herb solids can be prepared using
conventional pasta making equipment. The vegetable and herb pastas
produced by this invention have improved color, texture, structural
integrity, and flavor characteristics, in both the uncooked or dried state
and the cooked state, as compared with dried vegetable or herb pastas
currently available. An especially preferred vegetable pasta product of
this invention is an essentially egg-free and/or essentially oil-free
vegetable pasta product having improved color, texture, structural
integrity, and flavor characteristics, in both the uncooked or dried state
and the cooked state. An especially preferred herb pasta product of this
invention is an essentially egg-free and/or essentially oil-free herb
pasta product having improved color, texture, structural integrity, and
flavor characteristics, in both the uncooked or dried state and the cooked
state.
Vegetable pastas are provided which contain between about 4 to about 15
weight percent vegetable solids, preferably between about 6 and about 15
weight percent vegetable solids, and more preferably between about 6 to
about 9 weight percent vegetable solids. Herb pastas are provided which
contain between about 2 to 15 weight percent herb solids. When the herbs
used are individually quick frozen (IQF), the herb pasta preferably
contains about 2 to 5 weight percent herb solids, and more preferably
about 2 to 3 weight percent herb solids. If additional herb solids are
desired or needed for flavor, gently dried herbs can be added up to a
maximum of about 15 weight percent herb solids. When the herbs are gently
dried (e.g., freeze dried, air dried, and the like), the herb pasta
preferably contains about 4 to 15 weight percent herb solids, and more
preferably about 6 to 9 weight percent herb solids. The pastas of this
invention may contain both vegetable and herb solids, in which case, the
total amount of vegetable and herb solids should be in the range of about
4 to 15 weight percent. Preferably, the vegetable and herb pastas of this
invention are essentially egg-free. Preferably, the vegetable and herb
pastas of this invention are essentially oil-free. More preferably, the
vegetable and herb pastas of this invention are both essentially egg-free
and essentially oil-free.
The vegetable and herb pastas of this invention are prepared by first
forming a homogenous aqueous paste of flour and vegetable or herb solids
containing about 27 to about 33 weight percent water. The flour typically
has an average minimum protein content of greater than about 12 weight
percent and preferably in the range of about 12 to 13.5 weight percent.
The homogenous paste is then extruded to form pasta-shaped extrudates. For
purposes of this invention, the terms "pasta-shaped extrudates" or
"extrudates" are intended to include both three-dimensional shapes formed
with conventional extrusion techniques and dies of appropriate shape as
well as thin sheets formed using conventional roller-type pasta makers and
strips or other shapes cut from such thin sheets. The extrudates are dried
under high temperature and low relative humidity conditions. By carefully
controlling both the temperature and humidity during drying, a vegetable
or herb pasta is obtained which has, both before and after cooking, good
color, texture, integrity, and vegetable or herb flavor. Both
egg-containing and essentially egg-free vegetable and herb pastas can be
dried by the methods of this invention (i.e., relatively high temperatures
and relatively low humidity conditions) with excellent results.
The dried pastas of this invention have a moisture content of about 11.0 to
about 13.0 weight percent and a vegetable solids content of about 4 to
about 15 weight percent or a herb solids content of about 2 to 15 weight
percent. For purposes of this invention, "dried pasta" or "dried vegetable
pasta" or "dried herb pasta" is pasta having a moisture content of less
than about 13 weight percent and preferably less than about 12 weight
percent. Vegetables suitable for incorporation into vegetable pastas
prepared using the process of this invention include, but are not limited
to, beets, broccoli, carrots, celery, corn, green peppers, red peppers,
spinach, and tomatoes. Other vegetables may, if desired, also be employed.
If desired, mixtures of vegetable solids derived from different vegetables
can be used. It is also contemplated that the vegetables used may impart
color without flavor and vice versa. Herbs suitable for incorporation into
herb pastas prepared using the process of this invention include, but are
not limited to, oregano, basil, coriander, tarragon, onion, parsley, sage,
and garlic. Other herbs may, if desired, also be employed. If desired,
mixtures of herb solids derived from different herbs can be used. It is
also contemplated that the herbs used may impart color without flavor and
vice versa. In addition, and if desired, mixtures of vegetable and herb
solids can be used. The vegetable and herb pastas prepared by the process
of this invention offer excellent storage stability with minimal loss of
color, texture, and flavor and excellent retention of color, texture, and
flavor upon processing and subsequent cooking.
One object of the present invention is to provide a method of preparing
vegetable or herb pasta containing about 4 to about 15 weight percent
vegetable solids or about 2 to 15 weight percent herb solids, said method
comprising
(1) blending flour, vegetable or herb solids, and water to form a
homogenous paste with a water content of about 28 to about 33 weight
percent, wherein the flour has a minimum average protein content between
about 12 to about 13.5 weight percent;
(2) extruding the homogenous paste to form pasta-shaped extrudates; and
(3) drying the pasta-shaped extrudates under high temperature and low
relative humidity conditions, whereby a vegetable or herb pasta is
obtained with a moisture content of about 11 to about 13 weight percent
and vegetable solids content of about 4 to about 15 weight percent or herb
solids content of about 2 to 15 weight percent, wherein the vegetable or
herb pasta has, after processing and subsequent cooking, good color,
texture, integrity, and vegetable or herb flavor.
Another object of the present invention is to provide an essentially
egg-free vegetable or herb pasta containing about 4 to about 15 weight
percent vegetable solids or about 2 to 15 weight percent herb solids, said
pasta being prepared by a process comprising
(1) blending flour, vegetable or herb solids, and water to form a
homogenous paste with a water content of about 28 to about 33 weight
percent, wherein the flour has an average protein content between about 12
to about 13.5 weight percent, wherein the vegetable solids are derived
from a vegetable selected from the group consisting of beet, broccoli,
carrot, celery, corn, green pepper, red pepper, spinach, and tomato,
wherein the herb solids are derived from a herb selected from the group
consisting of oregano, basil, coriander, tarragon, onion, parsley, sage,
and garlic, and wherein the homogenous paste is essentially egg-free;
(2) extruding the homogenous paste to form pasta-shaped extrudates; and
(3) drying the pasta-shaped extrudates under high temperature and low
relative humidity conditions whereby an essentially egg-free vegetable or
herb pasta is obtained with a moisture content of about 11 to about 13
weight percent and vegetable solids content of about 4 to about 15 weight
percent or herb solids content of about 2 to 15 weight percent, wherein
the essentially egg-free vegetable or herb pasta has, after processing and
subsequent cooking, good color, texture, integrity, and vegetable or herb
flavor.
Still another object of this invention is to provide a method of preparing
a thin-walled vegetable or herb pasta containing about 4 to about 15
weight percent vegetable solids or about 2 to 15 weight percent herb
solids, said method comprising
(1) blending flour, vegetable or herb solids, and water to form a
homogenous paste with a water content of about 28 to about 33 weight
percent, wherein the flour is a blend of about 0 to about 100 weight
percent durum flour, about 0 to about 100 weight percent semolina flour,
and about 0 to about 100 weight percent hard red spring flour and has a
minimum average protein content between about 12 to about 13.5 weight
percent and wherein the vegetable solids are derived from a vegetable
selected from the group consisting of beet, broccoli, carrot, celery,
corn, green pepper, red pepper, spinach, and tomato or wherein the herb
solids are derived from a herb selected from the group consisting of
oregano, basil, coriander, tarragon, onion, parsley, sage, and garlic;
(2) extruding the homogenous paste to form thin-walled, pasta-shaped
extrudates; and
(3) drying the thin-walled, pasta-shaped extrudates under high temperature
and low relative humidity conditions, wherein
(a) the thin-walled, pasta-shaped extrudates is first dried at a
temperature of about 65.degree. to about 85.degree. C. and a relative
humidity of about 25 to about 60 percent for a time sufficient to form a
first partially-dried, thin-walled vegetable or herb pasta with a moisture
content of less than about 27 weight percent,
(b) the first partially-dried, thin-walled vegetable or herb pasta is then
dried at a temperature of about 75.degree. to about 115.degree. C. and a
relative humidity of about 26 to about 60 percent for a time sufficient to
form a second partially-dried, thin-walled vegetable or herb pasta with a
moisture content of less than about 19.0 weight percent, and
(c) the second partially-dried, thin-walled vegetable or herb pasta is
dried at a temperature of about 70.degree. to about 98.degree. C. and a
relative humidity of about 35 to about 60 percent for a time sufficient to
form a thin-walled vegetable or herb pasta with a moisture content of
about 11 to about 13 weight percent and vegetable solids content of about
4 to about 15 weight percent or herb solids content of about 2 to about 15
weight percent, wherein the thin-walled vegetable or herb pasta has, after
cooking, good color, texture, integrity, and vegetable or herb flavor.
These and other objects and advantages of the present invention will become
apparent through the following description of the preferred embodiments of
the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a method of producing vegetable or herb
pastas with high levels of vegetable or herb solids and to such vegetable
or herb pastas. Generally, the amount of vegetable solids is in the range
of about 4 to about 15 weight percent of the dried pasta containing
between about 11 to about 13 weight percent water. Preferably the
vegetable solids are between about 6 to about 9 weight percent of the
dried pasta. Typical vegetables suitable for incorporation into the pasta
of this invention include beet, broccoli, carrot, celery, corn, green
pepper, red pepper, spinach, and tomato; but, as indicated, other
vegetables may be utilized if desired. Generally, the amount of herb
solids is in the range of about 2 to about 15 weight percent of the dried
pasta containing between about 11 to about 13 weight percent water. For
IQF herbs, preferably the herb solids are between about 2 to about 5
weight percent of the dried pasta, and more preferably about 2 to 3 weight
percent of the dried pasta. For gently-dried herbs, preferably the herb
solids are between about 4 to about 15 weight percent of the dried pasta,
and more preferably about 6 to about 9 weight percent of the dried pasta.
Typical herbs suitable for incorporation into the pasta of this invention
include oregano, basil, coriander, tarragon, onion, parsley, sage, and
garlic; but, as indicated, other herbs may be utilized if desired.
In the first step of the present process, flour, vegetable or herb solids,
and water are blended together to form a homogenous mixture or paste with
a moisture content of about 28 to about 33 weight percent. When using IQF
herbs, the herbs are preferably rapidly thawed just prior to the blending
step to form an aqueous slurry. Preferably the moisture content of the
paste is about 29 to about 32 weight percent. Conventional pasta mixers
can be used for this blending step. The paste should be homogenous in
order to produce a consistent and uniform pasta product. It is generally
preferred that the homogenous mixture or paste is essentially egg-free.
For purposes of this invention, "essentially egg-free" means that the
vegetable or herb pasta contains less than about 0.1 weight percent egg
products (e.g., whole egg, egg white from whole egg, or dehydrated egg
white) or, more preferably, no egg products. It is also generally
preferred that the homogenous mixture or paste is essentially oil-free.
For purposes of this invention, "essentially oil-free" means that the
vegetable or herb pasta contains less than about 0.1 weight percent added
oil (e.g., olive oil) or, more preferably, no added oil. More preferably,
the homogenous mixture or paste is both essentially egg-free and
essentially oil-free.
High quality, wheat-based flours with mixograph values above 6 and a
falling number targeted at about 400 (at least 350 minimum) are preferred
in the practice of this invention. Mixograph values are a measure of
gluten strength. Values of about 1 to 3 correspond to weak gluten and
about 5 to 8 correspond to strong gluten. The falling number correlates
with alpha amylase activity and is a good indicator of sprout damage. High
alpha amylase activity in pasta products increases cooking losses. Higher
amounts of reducing sugars in the raw flours and in the final product will
result in softer textural characteristics in the cooked product. The flour
should be of the glutinous type and have a minimum average protein content
of about 12 to about 13.5 weight percent and preferably a minimum average
protein content of about 13 to about 13.5 weight percent. Preferred
wheat-based flours comprise 100 percent durum flours, 100 percent semolina
flours, blends of about 50 to about 100 parts by weight durum flour and 0
to about 50 parts by weight hard red spring flour, and blends of about 50
to about 100 parts by weight semolina flour and 0 to about 50 parts by
weight hard red spring flour. Limited amounts of proteinaceous materials
such as egg albumin or soy isolates can be incorporated into the blend to
modify textural properties if desired. Especially preferred wheat-based
flours include 100 percent durum flours, 100 percent semolina flours,
blends of about 50 to 100 weight percent durum flour and 0 to about 50
weight percent hard red spring flour, and blends of about 50 to 100 weight
percent semolina flour and 0 to about 50 weight percent hard red spring
flour, wherein the flour or flour blend has a minimum average protein
content between about 13 to about 13.5 weight percent. Generally flours
having a granulation size such that about 98 percent minimum pass through
a U.S. standard No. 70 sieve are acceptable.
Sufficient vegetable or herb solids and water are added to, and blended
with, the flour using conventional pasta-making equipment or mixers to
produce a paste of the desired water and vegetable or herb solids content.
The water content of the paste should be adjusted to allow for the
formation of suitable extrudates which will retain the desired shape until
that shape is set or hardened in the initial portion of the drying
process. Generally, water levels in the range of about 28 to about 33
weight percent are acceptable. The vegetable solids may be in the form of
a powder or an aqueous slurry. When using an aqueous slurry, a portion of
the required water to form the homogenous paste will come from the aqueous
slurry medium. The herb solids may be individually quick frozen (IQF) or
gently-dried herbs. When using IQF herbs, a portion of the required water
to form the homogenous paste will be derived from the water contained in
the IQF herbs. When using IQF herbs, if additional herb solids are desired
or needed for flavor, gently-dried herbs can also be added up to a maximum
of about 15 weight percent herb solids. For vegetable pastas, the amount
of vegetable solids added should be adjusted so that the final dried pasta
has a vegetable solids content in the range of about 4 to about 15 weight
percent based on the combined weight of the flour and vegetable solids.
For herb pastas, the amount of herb solids should be adjusted so that the
final dried pasta has a herb solids content in the range of about 2 to
about 15 weight percent based on the combined weight of the flour and herb
solids.
The vegetable solids can be prepared from the appropriate vegetables using
conventional techniques. For example, vegetable solids are preferably
prepared by spray drying slurries of the vegetable materials. For the
cases of tomato and beet powders, which are characterized by a
thermoplastic behavior due to their high sugar content, the use of powders
produced by spray drying in tall cooling towers is preferred. Such a
process would ensure good quality in the vegetable powders from the point
of view of color, flavor and nutrient retention. Vegetable powders
obtained by air drying, followed by grinding are acceptable, depending on
color and flavor characteristics. Although vegetable powders obtained by
freeze drying are excellent in quality, their high cost may limit their
utilization in commercial applications. Powders containing flow
conditioners or glidants may facilitate transport (feeding) operations
during the pasta making operations. Glidants such as precipitated silicas
may have a slightly detrimental effect on textural properties due to their
interaction with the protein fraction of the flour. Incorporation of
encapsulating materials with controlled water solubility such as proteins,
native or modified starches or hydrocolloids, during the spray drying
operation, will help in retaining color, flavor and nutrients during
drying of the vegetable slurries, during the pasta making operations and
during cooking. Suitable vegetables include beets, broccoli, carrots,
celery, corn, green peppers, red peppers, spinach, and tomatoes. Green
pepper, red peppers, broccoli and tomato are especially preferred.
Generally vegetable solids having an average particle size in the range of
about 5 percent maximum on U.S. standard No. 60 screen to about a minimum
of about 95 through a U.S. standard No. 14 screen are acceptable. As
noted, the vegetable solids may be added as a powder or as an aqueous
slurry. Introduction of the vegetable solids as a powder may facilitate
metering of the various streams in conventional pasta manufacturing
installations and allow easier stockpiling of the vegetable product for
use in the pasta manufacturing process. On the other hand, the use of
aqueous slurries will generally allow the avoidance of exposure of the
vegetable solids to the thermal treatment required to dry the vegetable
solids and will often result in a product with better flavor, color and
nutritional value. The use of a slurry may also reduce the overall
manufacturing cost since the dehydration process for preparing the
vegetable solids can be eliminated. When using vegetable solids above
about 6 percent, slurries may be too viscous for pumping or may prevent
proper flour hydration. In such cases, remaining vegetable solids need to
be introduced as powders.
The herb solids can be prepared from the appropriate herbs using
conventional techniques. For example, herb solids may be prepared by
individually quick frozen (IQF) techniques or by conventional
gently-drying techniques. Examples of such gently-drying techniques
include freeze drying, spray drying slurries of the herb materials
(especially in tall cooling towers), air drying, and the like. Powders
containing flow conditioners or glidants may facilitate transport
(feeding) operations during the pasta making operations. Glidants such as
precipitated silicas may have a slightly detrimental effect on textural
properties due to their interaction with the protein fraction of the
flour. Incorporation of encapsulating materials with controlled water
solubility such as proteins, native or modified starches or hydrocolloids,
during the spray drying operation, will help in retaining color, flavor
and nutrients during drying of the herb slurries, during the pasta making
operations and during cooking. Suitable herbs include oregano, basil,
coriander, tarragon, onion, parsley, sage, and garlic. Generally herb
solids having an average particle size in the range of about 5 percent
maximum on U.S. standard No. 60 screen to about a minimum of about 95
through a U.S. standard No. 14 screen are acceptable. As noted, the herb
solids may be added in the form of a gently-dried powder or a slurry from
an IQF material. When using IQF herbs, the herbs are preferably thawed
rapidly just prior to the pasta-making procedure by adding adequate water
with strong mixing to form a slurry with the appropriate solids content.
The resulting thawed herbs are then added in the form of an aqueous
slurry. Generally, herb pastas prepared using IQF herbs have improved
color and flavor retention as compared to herb pastas prepared using
gently-dried herbs. When using IQF herbs, the herb solid content of the
dried pasta is generally in the range of about 2 to 5 weight percent, and
preferably about 2 to 3 weight percent. When using gently-dried herbs, the
herb solid content of the dried pasta is generally in the range of about 4
to 15 weight percent, and preferably about 6 to 9 weight percent. Mixtures
of IQF and gently-dried herbs may also be used if desired to achieve good
flavor and/or color intensity. When using IQF herbs or other slurried
forms, slurries containing more than about 8 weight percent solids may
prevent proper flour hydration. In such cases, remaining herb solids, if
desired, should be introduced in the form of a gently-dried powder.
Other additives or ingredients may also, if desired, be added to the paste.
Such additives include pH modifiers such as food-grade hydrochloric acid,
sodium, hydroxide, and the like; salt or other spices; disodium phosphate;
glyceryl monostearate; egg white powder; wheat gluten; whey solids; soy
protein isolates; and encapsulated vitamins. Such additives can be used to
enhance the flavor or nutritional value of the pasta or to provide
improved physical properties for the paste such as reduced viscosity or
improved lubrication to assist in the extrusion process. Generally,
additives, such as extrusion aids, pH modifiers, and encapsulated
vitamins, will be present at relatively low levels, i.e., less than about
2 weight percent and preferably less than about 1.5 weight percent, based
on the total weight of the dried pasta. Protein-containing materials such
as soy protein isolates and egg whites may be added up to a level of about
10 percent.
For chlorophyll-containing vegetables (e.g., broccoli, celery, green
pepper, spinach, and the like) or chlorophyll-containing herbs (e.g.,
basil, oregano, coriander, and the like), it may be desirable to adjust
the pH of the homogenous paste to a value of about 5 to about 9 and
preferably about 6 to about 8 prior to extrusion. For
carotenoid-containing vegetables such as carrots and tomato and
betalain-containing vegetables such as beets, a pH in the range of about 4
to about 7 pH units may be preferred. Paste containing vegetable or herb
solids outside these pH ranges may also be used; in other words, although
it may be preferable to adjust the pH with specific vegetables and herbs,
it is not necessary.
Once the homogenous paste is formed, the paste is extruded or otherwise
shaped using conventional pasta making techniques. For example, the
homogenous paste can be forced through the holes of an extruder die or can
be pressed between rollers to obtained the desired shape. Extrudates
formed using an extruder die can be cut to the desired length. Extrudates
formed using rollers will be in the form of thin sheets which can then be
cut into thin strips and to length before further processing. All
conventional pasta shapes can be used in the practice of this invention
including, for example, spaghetti, vermicelli, fettucini, linguine, ziti,
elbow spaghetti, orqu, shell, elbow macaroni, rigatoni, macaroni, twist
rings, mafalda, alphabets, lasagna, spirals, manicotti, angel hair,
noodles, kid's shapes such as teddy bears and the like. Thin-wall
extrudates or pasta shapes are, however, especially preferred since they
generally require shorter drying times. For purposes of this invention,
"thin wall" means a wall thickness of less than about 0.035 inches,
preferably in the range of about 0.014 inches to about 0.031 inches.
Once formed, the pasta-shaped extrudates of this invention are dried under
controlled conditions using high temperature and low relative humidity to
produce a dried pasta with a moisture content of about 11 to about 13
weight percent and preferably about 12 to about 12.5 weight percent and
which has good color, texture, and integrity. For purposes of this
invention, "low relative humidity" is intended to mean a relative humidity
in the range of about 25 to about 65 percent during the peak drying
period, preferably in the range of about 25 to about 60 percent, and more
preferably in the range of about 25 to 50 percent. For purposes of this
invention, the "peak drying period" is that portion of the drying profile
wherein the majority of the drying takes place; normally the peak drying
period includes the initial and middle portion of the drying profile
(i.e., at elevated temperatures) but generally does not include the final
cool down portion at the end of the drying profile. It is important that
the extrudates to be dried have an initial moisture content of at least 28
weight percent and preferably about 29 to about 33 weight percent. If the
initial moisture content is too low, i.e., less than 28 weight percent,
or if the relative humidity is too low, i.e., less than about 25 percent,
it may be difficult to avoid significant structural damage to the final
product during drying. By controlling the drying conditions, a good
quality pasta can be produced without significant deterioration or
destruction of the color, flavor, and nutrients associated with the
vegetable or herb used to prepare the pasta. The drying profiles used in
this invention are designed to allow for controlled and rapid removal of
the water from the pasta with minimal structural stresses to prevent or
minimize cracking, checking, splitting, and blistering of the pasta
shapes. The present drying process generally limits the duration of the
exposure of the vegetable or herb pasta to elevated temperatures while
still providing a relatively crack-, check-, split-, blister-, and
structural stress-free pasta product. It is generally preferred that the
total time the vegetable or herb pasta be exposed to temperatures in
excess of about 75.degree. C. during the drying process is less than about
4.5 hours and more preferably less than about 3.5 hours. As noted above,
thin-walled pasta is especially preferred for the practice of this
invention since such pasta can generally be dried significantly faster
than thick-walled pasta. Generally the drying processes described herein
can be used for drying both egg-containing and essentially egg-free pasta
products as described herein. These drying processes are especially
adapted and suitable for preparing essentially egg-free, dried pasta
products.
One preferred drying profile involves (a) drying the pasta-shaped
extrudates at a temperature of about 65.degree. to about 85.degree. C. and
a relative humidity of about 25 to about 60 percent for a time sufficient
to form a partially-dried vegetable or herb pasta with a moisture content
of less than about 27 weight percent, and (b) drying the partially-dried
vegetable or herb pasta at a temperature of about 75.degree. to about
115.degree. C. and a relative humidity of about 26 to about 60 percent for
a time sufficient to dry the vegetable or herb pasta. Another preferred
drying profile involves (a) drying the pasta-shaped at a temperature of
about 65.degree. to about 85.degree. C. and a relative humidity of about
25 to about 60 percent for a time sufficient to form a first
partially-dried vegetable or herb pasta with a moisture content of less
than about 27 weight percent, (b) drying the first partially-dried
vegetable or herb pasta at a temperature of about 75.degree. to about
115.degree. C. and a relative humidity of about 26 to about 60 percent for
a time sufficient to form a second partially-dried vegetable or herb pasta
with a moisture content of less than about 19.0 weight percent, and (c)
drying the second partially-dried vegetable or herb pasta at a temperature
of about 70.degree. to about 98.degree. C. and a relative humidity of
about 35 to about 60 percent for a time sufficient to dry the vegetable or
herb pasta. Drying profiles having more than three discrete steps can also
be used and may, in some cases, be preferred. A cooling section with
temperatures of about 25.degree. to 30.degree. C. can be used to temper
the product.
Preferably the drying regime involves first drying at a temperature of
about 60.degree. to about 70.degree. C. for a relatively short time, i.e.,
about 5 to about 30 minutes, to set the shape of the extrudates, followed
by drying at a higher temperature of about 70.degree. to about 80.degree.
C. for about 15 to about 60 minutes, followed by drying at a lower
temperature of about 65.degree. to about 75.degree. C. for about 60 to
about 215 minutes, and finally drying at about ambient temperature for
about 30 to about 120 minutes, while maintaining the relative humidity
throughout the drying process in the range of about 25 to about 60 percent
and preferably in the range of about 25 to about 50 percent. For example,
the drying profiles included in the following Tables I, II, and III have
been found to be satisfactory for a thin-walled pasta containing about 6
weight percent vegetable or herb solids. Additionally, based on both pilot
plant and commercial operations for a vegetable pasta, a preferred drying
profile is shown in Table III.
TABLE I
______________________________________
Typical Drying Profile
Temperature
Relative
Segment Time (min.) (.degree.C.)
Humidity (%)
______________________________________
1 15 80-85 25-30
2 30 110-120 25-30
3 45 95-100 30-40
4 60 85-90 25-35
5 90 25-30 25-30
______________________________________
TABLE II
______________________________________
Typical Drying Profile
Temperature
Relative
Segment Time (min.) (.degree.C.)
Humidity (%)
______________________________________
1 10 60-70 50-70
2 35 70-80 40-60
3 215 65-75 40-60
4 35 30-40 70-80
5 45 25-30 45-50
______________________________________
TABLE III
______________________________________
A Preferred Drying Profile
Temperature
Relative
Segment Time (min.) (.degree.C.)
Humidity (%)
______________________________________
1 1 25 50
2 9 74 60
3 35 68 60
4 215 74 51
5 35 36 80
6 45 25 50
______________________________________
Of course, the drying profiles included in Tables I-III are intended only
as examples of suitable drying profiles. Many other time, temperature, and
relative humidity combinations can be used so long the vegetable or herb
pasta is exposed to high temperatures of about 70.degree. to about
115.degree. C. with a residence time depending on air temperature during
the early portion of the drying cycle, the relative humidity remains about
40 to about 60 percent during the drying cycle, the final moisture content
of the dried pasta is in the range of about 11 to about 13 weight percent,
and the resulting dried pasta has good color, texture, integrity, and
flavor. Moreover, a those skilled in the art will realize, preferred
drying profiles within these ranges can vary with other operational
parameters including, for example, scale of the manufacturing facility and
actual equipment used. Instead of having discrete temperature steps, i.e.,
step functions, as suggested in the Tables above, the temperature and
relative humidity can also be varied in a more "continuous" manner. For
example, a continuous profile similar to the step profile in Table I might
consist of slowly and continuously raising the temperature from about
80.degree. C. to about 120.degree. C. over about 15 minutes, holding at
about 120.degree. C. for about 30 minutes, slowly and continuously
lowering the temperature to about 90.degree. C. over about 60 minutes, and
then slowly and continuously lowering the temperature to ambient
temperature (about 25.degree. C.) over about 90 minutes.
As noted above, the process of this invention can be implemented using
conventional pasta making equipment, including convention pasta drying
ovens. The drying ovens must, of course, be capable of controlling the
temperature and relative humidity to which the pasta shapes are exposed as
a function of time. Generally, forced air drying ovens with discrete or
separate drying zones and separate temperature and humidity controls for
each drying zone are preferred. Separate drying zones allow the
temperature and relative humidity to be easily varied and controlled as
the pasta passes through the drying oven. Continuous, multi-conveyor belt
type dryers where the pasta shapes drop from one belt to another are
especially suited for the practice of this invention; the temperature and
relative humidity can be controlled such that the pasta on each belt can
be exposed to the desired temperature and humidity conditions. Separate
drying ovens connected in series, where each oven has its own separate
temperature and relative humidity controller, are generally preferred.
Preferably the drying oven or ovens are forced air types which allows for
better control of the humidity near the surface of the pasta shapes.
Especially in the early stages of the drying process, water vapor removed
from the pasta can raise the relative humidity near the pasta surface to
levels higher than desired, thereby slowing down the drying process and
resulting in a less desirable product. By removing this potential "layer"
of high humidity near the pasta surface, the humidity can be controlled
with the ranges desired in the present process. High capacity lines (in
the range of 6000 lbs/hr or above) may result in problems in controlling
the percentage of relative humidity in the predryer. Accurate temperature
and percent relative humidity must be controlled in the predryer to assure
good quality in terms of color, flavor, nutrients, and structural
integrity.
The vegetable and herb pastas of this invention have good color, texture,
integrity, and flavor both before and after cooking. The pastas of this
invention also have excellent storage stability. For example, vegetable
pasta produced by this invention has a storage stability greater than nine
months if protected from light; the good color, texture, integrity, and
vegetable flavor both before and after cooking is not significantly
reduced upon such storage. Storage stability can be increased even further
if, in addition to protection from light, the pasta is protected from
oxygen by, for example, packaging in an inert atmosphere such as nitrogen,
or from high relative humidities. Protective packaging to minimize light
and oxygen contact will be preferred if storage is expected to be at high
relative humidities and high temperatures.
The following examples are provided to illustrate the invention and not to
limit the invention.
Example 1. This example illustrates the manufacture of a vegetable pasta
with various types of wheat flours using the process of this invention.
Samples containing 6 weight percent tomato solids with 100 percent durum,
100 percent hard red spring (HRS), or blends of the aforementioned flours
were evaluated for process performance and product quality. The data
relating to texture and color are provided in Table IV. No significant
difference was observed in the process performance of the various mixes.
Generally, samples prepared with 100 percent durum flours were superior in
overall acceptability and had better color and texture. The other samples
were, however, acceptable. Thus, the durum flours, probably because of the
type of proteins they contain, are generally preferred for the
manufacturing of vegetable pasta.
TABLE IV
______________________________________
Variation of Flour Type
Texture
Break
Work Strength Color
Flour (lb-cm/g) (lb/g) L a b
______________________________________
durum 3.93 72 32.31 16.55 28.42
50/50 3.42 62 29.33 15.40 32.89
durum/HRS
HRS 3.46 65 24.49 12.90 19.50
______________________________________
Texture measurements in the above Table were determined using a FTC Texture
Test System. Color parameters were determined with a Minolta Colorimeter:
L is a measurement of the white-gray color component (lightness); a is a
measurement of the yellow-blue component (chromaticity); and b is a
measurement of the red-green component (chromaticity).
Example 2. This example illustrates the use of high vegetable solids in the
successful manufacture of vegetable pasta. The process performance and
final quality of samples prepared with various levels of tomato solids
ranging from 3 to 15 weight percent (dry basis) and 100 percent durum
flour were evaluated. Variation in final moisture content upon extrusion
was observed in samples as a function of the level of solids added.
Results, as indicated in Table V below, indicate that upon an increase in
tomato solids concentration, the textural properties declined in
acceptability, while color and flavor increased in intensity. All samples
were found to be acceptable, however. A maximum in desired flavor
intensity was found to be around 9 to 12 weight percent vegetable solids
for products undergoing conventional cooking. Much better flavor retention
was observed in products that were microwaved for an equivalent degree of
cooking.
TABLE V
______________________________________
Variation of Vegetable Content
Texture
Tomato Break
Solids Work Strength Color
(%) (lb-cm/g) (lb/g) L a b
______________________________________
0 3.93 72 45.90 -2.78 30.97
6 3.43 63 35.41 17.83 28.25
12 3.19 57 26.04 15.82 18.89
15 2.91 54 27.92 16.97 19.28
______________________________________
Color parameters were determined with a Minolta Colorimeter: L is a
measurement of the white-gray color component (lightness); a is a
measurement of the yellow-blue component (chromaticity); and b is a
measurement of the red-green component (chromaticity). Texture was
determined using a FTC Texture Test System.
Example 3. This example illustrates that pH adjustment did not
significantly modify the green color of vegetable pasta containing
broccoli. The pH of the pasta has been reported to have a significant
effect on chlorophyll stability. Using broccoli pasta with pH in the range
of from 5.0 to 9.0, it was found that the water and temperature parameters
during the drying cycle were more important, as measured by product
quality, than the pH. Generally, however, a brighter green color was
obtained at pH 7.8. The pH had little effect on textural properties. As
far as mouthfeel and overall acceptability, pH had little effect; all
samples were acceptable.
TABLE VI
______________________________________
Variation of pH
Texture
Break
Strength
Color
Blend pH (lb/g) L a b
______________________________________
durum -- 44.44 45.90 -2.78 30.97
durum + 6%
broccoli 5.0 48.25 26.87 -3.37 19.60
durum + 6%
broccoli 7.8 49.28 30.32 -3.54 20.67
durum + 6%
broccoli 9.0 49.65 28.25 -3.10 19.57
______________________________________
Texture measurements in the above Table were determined using an Instron
Universal Machine. Color parameters were determined with a Minolta
Colorimeter: L is a measurement of the white-gray color component
(lightness); a is a measurement of the yellow-blue component
(chromaticity); and b is a measurement of the red-green component
(chromaticity).
Example 4. An experimental design was conducted in a pilot plant to
evaluate the influence of the several experimental variables on tomato
pasta quality. The experimental design used was the Taguchi design as
described in "Introduction to Quality Engineering" (America Supplier
Institute, Dearborn, Michigan; Version 2.2; 1992). This experimental
design allowed the evaluation of eight experimental variables and three
levels for each variable. The experimental variables and their levels are
shown in Table VII. Dependent variables measured included texture (as
measured on an Instron Universal Machine), color (as measured with a
Hunter Colorimeter), and amount of solids lost upon cooking.
TABLE VII
______________________________________
Experimental Variables
Experimental Experimental Value
Variables Level 1 Level 2 Level 3
______________________________________
Addition of Powder Slurry --
Vegetable Solids
Solids Added (%)
3.0 6.0 9.0
Flour Type 100/0 75/25 50/50
(% durum/% HRS)
Water Setting 2.8 3.2 3.6
Peak Dryer Temp.
72 86 100
(Dry Bulb, .degree.C.)
Relative Humidity
26 30 34
(%) at Peak Temp.
Dry Blend 15 45 120
Time (minutes)
pH 5.0 6.0 7.0
______________________________________
The results of the experimental design suggest, at least within the ranges
of independent variable examined, that:
(1) Process water level is significant in controlling the textural
properties of the final product. Moisture level of the pasta prior to
drying is also important relative to the structural stresses in the dry
pasta. The form in which the vegetable solids are added (i.e., powder or
slurry) and the dry bulb temperature of the air influence the texture of
the cooked product to a lesser degree.
(2) Vegetable solids level, type of flour, and water levels used in the
manufacturing of the pasta are important variables relative to the amount
of solids lost during cooking. Generally, better results are obtained when
100 percent durum flour is utilized.
(3) Important variables which influence color are level of vegetable
solids, form in which the vegetable solids are added (i.e., powder or
slurry), and water setting.
Based on results of the experimental design, a "paper champion"--i.e., the
values of the variables providing the best overall product within the
criteria of the Taguchi design--was determined. The values for each
variable for the "paper champion" are provided in the following Table
VIII. It is expected that a product manufactured using these composition
and process parameters would have a good to excellent quality profile. As
those skilled in the art will realize, the optimum values for any of these
parameters may depend, at least to some extent, on the exact equipment
used and the scale of the manufacturing operation.
TABLE VIII
______________________________________
Overall Results -- "Paper Champion"
Experimental Variables
"Paper Champion"
______________________________________
Addition of Vegetable
Powder
Solids
Solids Added (%) 6.0
Flour Type (% durum/
75/25
% HRS)
Water Setting high
Peak Dryer Temp. (Dry
100
Bulb, .degree.C.)
Relative Humidity (%)
34
at Peak Temp.
Dry Blend Time 120
(minutes)
pH 7.0
______________________________________
Example 5. Under controlled manufacturing conditions, initial moisture
content as well as humidity and temperature in the predryers can affect
the color of chlorophyll-containing vegetable and herb pastas prepared
using durum flours, semolina flours, hard red spring flours, and blends
thereof. Accurate control of the temperature and humidity conditions in
the predryer appears to be influential factors on product quality,
particularly color. Conditions in the final dryer had reduced influence on
color retention, due to the lower moisture content of the product. Since
humidity control is not normally effected in the shaker, initial moisture
content of the pasta can be more important during this operation. Final
moisture content of the material coming out of the shaker has a
significant effect on color retention in the final product, since it
determines the reactivity of the material entering the predryer. Plant
trials conducted under a variety of process conditions for the drying
cycle suggest, particularly for the case of chlorophyll-containing
products, that the combination temperature/relative humidity is important
for color retention during drying. Chlorophyll degradation and conversion
to brown pigments (pheophytins) occurs at high moisture contents and high
temperatures. Thus, drying profiles that would allow the rapid dehydration
of the pasta without creating significant structural stress are expected,
based on this invention, to result in a good quality product without the
addition of additives to prevent such product defects.
Example 6. Experiments conducted on vegetable and herb pasta of different
shapes (i.e., elbows, elbow spaghetti, fettuccine, mafalda, kid's shapes
such as Christmas shapes, etc.) and thicknesses (conventional and thin
wall), generally indicated that better color retention was obtained with
thin-walled pastas independent of the actual shape. Conventional thickness
pasta, however, gave acceptable results. Color and flavor retention upon
cooking was also improved when using thin-walled products, probably
because of the decreased time required for cooking. Generally, better
cooked properties (e.g., color and flavor) were obtained when the pastas
were microwaved, as opposed to conventional cooking.
Example 7. This example illustrates the preparation of several basil
fettuccines wherein the pH, solids content, and form of added basil were
varied. The basil added included IQF basil, freeze-dried basil, and
mixtures of IQF and freeze-dried basil. The appropriate basil-containing
slurries were prepared in a Breddo mixture and then added to the pasta
mixture (prepared with durum flour) at the preconditioner point of the
pasta manufacturing line. The amounts of water and basil (IQF and/or
freeze-dried) used to prepare the slurries were adjusted to provide the
desired herb solids content and a residual moisture content of the formed
pasta of about 30 to 32 weight percent. The formed pasta was then dried to
a final moisture content of about 11 to 13 weight percent using the
relatively high temperature and relatively low humidity drying profile of
Table IX. The total drying time was about 5.7 hours. The peak drying
period (generally segments 1-12 with a total duration of about 4.3 hours)
was at a temperature of up to about 74.degree. C. and a relative humidity
of about 50 to 62 percent. During segments 1-5, the temperature was raised
to the peak temperature levels while maintaining the humidity at about 50
percent. Segments 6-12 (total time of 4 hours) essentially represent a
plateau wherein the temperature was in the range of about 68.degree. to
74.degree. C. and the relative humidity was about 50 to 62 percent; this
period likely accounts for most of the drying. Finally, during segments
13-20, the pasta was allowed to cool to ambient levels.
TABLE IX
______________________________________
Drying Profile for Basil Fettuccines
Temperature
Relative
Segment Time (min.) (.degree.C.)
Humidity (%)
______________________________________
1 1 25 50
2 6 35 50
3 6 45 50
4 6 55 50
5 6 65 50
6 9 74 60
7 4 72 60
8 4 70 62
9 30 68 62
10 4 70 51
11 4 72 51
12 180 74 51
13 10 68 80
14 10 60 80
15 10 52 80
16 10 44 80
17 10 36 80
18 10 32 50
19 10 28 50
20 10 25 50
______________________________________
The following samples were prepared using durum flour: (1) pasta containing
2 weight percent basil solids using IQF basil; (2) pasta containing 4
weight percent basil solids using a mixture of IQF basil (2 weight
percent) and freeze-dried (FD) basil (2 weight percent); and (3) pasta
containing 15 weight percent basil using freeze-dried basil. Samples of
the 4 weight percent basil-containing pasta were prepared having an acidic
pH of 3.6, a neutral pH of 6.7, and an alkaline pH of 9.2. Excellent green
color was observed in each of the samples in both the dried and cooked (7
minutes) form. Colorimeter data is presented in Tables X (uncooked dried
pasta) and XI (cooked pasta).
TABLE X
______________________________________
Color for Uncooked Dried Pasta
Color
Basil Solids L a b
______________________________________
2% IQF 29.33 -2.60 17.71
2% IQF/2% FD at pH 9.2
23.62 -1.49 9.39
2% IQF/2% FD at pH 6.7
27.51 -2.45 14.10
2% IQF/2% FD at pH 3.6
26.12 -0.93 12.30
15% FD 26.02 -2.06 7.21
______________________________________
TABLE XI
______________________________________
Color for Cooked Pasta
Color
Basil Solids L a b
______________________________________
2% IQF 46.56 -5.34 17.42
2% IQF/2% FD at pH 9.2
29.30 -4.08 15.30
2% IQF/2% FD at pH 6.7
29.24 -4.18 15.25
2% IQF/2% FD at pH 3.6
33.82 -3.53 16.71
15% FD 27.21 -3.62 14.53
______________________________________
Color parameters were determined with a Minolta Colorimeter: L is a
measurement of the white-gray color component (lightness); a is a
measurement of the yellow-blue component (chromaticity); and b is a
measurement of the red-green component (chromaticity).
Each basil pasta had good color in the dried and cooked state and good
flavor in the cooked state. Pasta prepared using IQF herbs (either alone
or combined with freeze-dried herbs) had especially good flavor and color
after cooking, with the characteristic flavor notes of fresh basil.
Generally, the neutral pH and alkaline pH pastas were superior to the
acidic pH pasta; all samples were, however, acceptable. The pastas
containing mixtures of IQF and freeze-dried basil and a pH in the range of
about 6.7 and 9.2 were considered excellent in both the dried and cooked
form in terms of color and flavor.
Example 8. This example illustrates the use of encapsulated tomato solids
to prepare a tomato pasta. Dehydrated tomato powder (not less than 93
percent passing through a U.S. Standard No. 30 sieve and not more than 3
percent passing through a U.S. Standard No. 140 sieve) was coated with the
following encapsulation composition:
______________________________________
Gelatin 2.0%
Alginate 1.0%
Pectin 1.0%
Calcium sulfate 0.12%
Water 95.88%
______________________________________
The tomato solids were encapsulated in a fluidized bed coater (Glatt Air
Techniques, Model GPCG-5) operated at an inlet air temperature below
60.degree. C. and a product temperature below 50.degree. C. The
encapsulating ingredients were solubilized in hot water and slowly applied
to the tomato powder in the fluidized bed coater over a two hour period to
provide a coated tomato powder having about 6 to 10 weight percent
encapsulating material (dry basis). Encapsulated tomato solids were
blended with 100 percent durum flour to provide a tomato pasta (upon
drying) which contains 6 weight percent tomato solids. The blended mixture
was then processed in a conventional extruder (Demaco, single screw type).
Formed pasta was then dried using the high temperature and low relative
humidity conditions of this invention. Both fresh and dried encapsulated
tomato pasta exhibited better characteristics in terms of color and flavor
retention upon cooking than similar tomato pasta prepared using
unencapsulated tomato solids.
Other encapsulating compositions and/or other vegetable and herb solids can
be used in a similar manner to form encapsulated vegetable and herb pastas
with excellent color and flavor retention upon cooking. Likewise, other
methods for encapsulation can also be used. For example, the vegetable or
herb solids could be encapsulated by adding the encapsulation composition
to a slurry of the vegetable or herb materials prior to formation of the
vegetable or herb solids by spray drying.
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